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Basic Principle of Grinding Machine 1
Basic Principle of Grinding Machine 1
Grinding should be used when size tolerance specifications are beyond the capability
of turning.
It is also applied if the requirements of surface finish are too tight for hard turning.
The grinding ball continuously rotates over and over causing the grinding media to
fall over and over onto the material that is in the grinding ball to be made into a fine powder.
This process may take some time. Depending on the material to be ground and how fine it
needs to be ground down. However, this process is automated and makes it possible for the
process to take far fewer people to accomplish the work. In many grinding balls the material
is able to put into one end and then come out of the other end when it is sufficiently ground
down. This makes the process even more automated and less labor intensive
vertical spindle
l
horizontal spindle
Machine parts
1)base
functions
Serves as a foundation member for all the other parts which rest upon
it. It carries the column at its one end.
2)column
3)knee
The rigid gray iron casting that slides up and down on the vertical way
of the column face.
4)saddle
5)table
The table rest on ways on the saddle and travels longitudinally. The
top of the table is accurately finished and T-slots are provided for
clamping the work and other fixtures on it.
Machine parts
1)base
functions
Serves as a foundation member for all the other parts which rest upon
it. It carries the column at its one end.
2)column
3)knee
The rigid gray iron casting that slides up and down on the vertical way
of the column face.
4)saddle
5)table
The table rest on ways on the saddle and travels longitudinally. The
top of the table is accurately finished and T-slots are provided for
clamping the work and other fixtures on it.
Wheel
A.Grinding wheel materials.
Aluminum Oxide (A)
Silicon Carbide (C)
Diamond (D, MD, SD)
Cubic Boron Nitride (B)
B.Available wheel shapes.
1.Straight wheel
To the right is an image of a straight wheel. These are by far the most common style of wheel
and can be found on bench or pedestal grinders. They are used on the periphery only and
therefore produce a slightly concave surface (hollow ground) on the part. This can be used to
advantage on many tools such as chisels.
Straight Wheels are the kind of generally used for cylindrical, centreless, and surface grinding
operations. Wheels of this form vary greatly in size, the diameter and width of face naturally
depending upon the class of work for which is used and the size and power of the grinding
machine.
2.Cylinder or wheel ring
Cylinder wheels provide a long, wide surface with no center mounting support (hollow).
They can be very large, up to 12" in width. They are used only in vertical or horizontal
spindle grinders. Cylinder or wheel ring is used for producing flat surfaces, the grinding
being done with the end face of the wheel.
3.Tapered wheel
A straight wheel that tapers outward towards the center of the wheel. This arrangement is
stronger than straight wheels and can accept higher lateral loads. Tapered face straight wheel
is primarily used for grinding thread, gear teeth etc.
4.Straight cup
Straight cup wheels are an alternative to cup wheels in tool and cutter grinders, where having
an additional radial grinding surface is beneficial.
5.Dish cup
A very shallow cup-style grinding wheel. The thinness allows grinding in slots and crevices.
It is used primarily in cutter grinding and jig grinding.
6.Saucer wheel
A special grinding profile that is used to grind milling cutters and twist drills. It is most
common in non-machining areas, as sawfilers use saucer wheels in the maintenance of saw
blades.
7.Diamond wheel
Diamond wheels are grinding wheels with industrial diamonds bonded to the periphery.
They are used for grinding extremely hard materials such as carbide cutting tips, gemstones
or concrete. The saw pictured to the right is a slitting saw and is designed for slicing hard
materials, typically gemstones.
8.Diamond mandrels
Diamond mandrels are very similar to their counterpart, a diamond wheel. They are tiny
diamond rasps for use in a jig grinder doing profiling work in hard material.
9.Cut off wheels
Cut off wheels, also known as parting wheels, are self-sharpening wheels that are thin in
width and often have radial fibres reinforcing them. They are often used in the construction
industry for cuttingreinforcement bars (rebar), protruding bolts or anything that needs quick
removal or trimming. Most handymen would recognise an angle grinder and the discs they us
Criteria of the wheel
1.Grain size,
from 8 (coarsest) 600 (finest), determines the physical size of the abrasive grains in the
wheel. A larger grain will cut freely, allowing fast cutting but poor surface finish. Ultra-fine
grain sizes are for precision finish work.
2.Wheel grade,
from A (soft) to Z (hard), determines how tightly the bond holds the abrasive. Grade affects
almost all considerations of grinding, such as wheel speed, coolant flow, maximum and
minimum feed rates, and grinding depth.
3.Grain spacing,
or structure, from 1 (densest) to 16 (least dense). Density is the ratio of bond and abrasive to
air space. A less-dense wheel will cut freely, and has a large effect on surface finish. It is also
able to take a deeper or wider cut with less coolant, as the chip clearance on the wheel is
greater.
4.Wheel bond,
how the wheel holds the abrasives, affects finish, coolant, and minimum/maximum wheel
speed.
Vitrified (V)
Resinoid (R)
Silicate (S)
Shellac (E)
Rubber (R)
Oxychloride (O)
C.Wheel balancing
1. Remove out the wheel adaptor and the balancing weight
2. Before install the new grinding wheel, check the grinding wheel by knocking the
grinding wheel and differential the sound of the grinding wheel
3. After mounting the new grinding wheel fix the unit onto the spindle and rough true
grinding wheel so that it has a true roundness.
4. Remove out the grinding wheel from machine and insert the balancing arbour into the
griding wheel flange.
5. Place the grinding wheel balancing stand and level the unit by checking the level
gauge.
6. Place the grinding wheel with arbour onto the balancing stand.
7. Turn the grinding wheel run freely until it comes to a rest, the bottom point may be
the heavier side(W).
8. Then tighten one of the balancing weight at opposite side of the heavier point(W).
9. And then tighten two pieces balancing weights(AA) in a symmetry.
10. Adjust an each opening angle(A) must be according to the amount of inbalance.
11. Adjust the position of the balancing weight repeatedly until the grinding wheel is in
the good balance when turned in any positions on the balancing stand.
Accessories
A.Clamping techniques used in the grinding processes
Method for grinding a machine component having at one longitudinal axial end a journal and
at its other longitudinal axial end an interior recess having a rotationally symmetrical surface,
comprising rotating the machine component about a longitudinal axis thereof, grinding
exterior surfaces thereof with a first grinding wheel and grinding said surface of said interior
recess with a second grinding wheel, a workpiece headstock, a tailstock, and at least one
steady being provided for clamping said machine component during grinding, wherein said
grinding method comprises the following sequential steps:
d) in the second clamped condition, moving the second grinding wheel from the idle
position, inserting the second grinding wheel is said interior recess and grinding therewith
said rotationally symmetrical surface of said interior recess;
e) returning said second grinding wheel to its idle position, rendering said steady is
inactive, and reinstating the first clamped condition;
f) effecting a third clamped condition n which said clamping jaws of said chuck of said
workpiece headstock are released from said journal and drawn axially into said chuck such
that said machine component is then clamped only between the centering tip of said
workpiece headstock and said tailstock sleeve;
g) in the third clamped condition, with the first grinding wheel grinding a circumference of
said journal.
ASSIGNMENT 2
GRINDING MACHINE